Fabric coated with light reflecting filler and acrylic polymer



3,296,023 FABRIC COATED WITH LIGHT REFLECTING FILLER AND ACRYLEC POLYMERAlexander John Leaderman, Pikesville, and Gordon Loeh, Baltimore, Md,assignors to Rochland Bleach and Dye Works, Inc, Baltimore, Md., acorporation of Maryland No Drawing. Filed Mar. 11, 1964, Ser. No.351,239 4 Claims. (Cl. 117-161) This invention relates to a novel fabricand more particularly to a fabric having a novel coating thereon and isa continuation-in-part of our copending application Serial No. 251,718,filed January 16, 1963, now abandoned.

Heretofore, fabrics have been coated and/ or lined with variousmaterials in an attempt to impart thermal insulating characteristicsthereto. As generally understood, the desired thermal insulatingqualities of such a fabric is a balance of its reflectivity,transmittance and adsorptivity characteristics. Thus, an ideal fabricfrom a thermal insulating viewpoint is one which displays not only highreflectivity but also sufficient transmittance to permit natural lightto pass therethrough in amounts sufiiciently ample so that completedependence on artificial lighting systems is not required duringdaylight hours as well as a minimum absorptivity with minimumrereflectance of the energy or heat absorbed. Accordingly, fabricsprovided with certain resinous materials, which are opaque, while theymay impart high reflectivity to the fabric, they generally reduce itstransmittance characteristics to a level, such that substantially nonatural light passes through the material. In instances where such afabric is employed as a drapery material or drapery liner material,artificial lighting systems must necessarily be employed to illuminateduring daylight hours an area where such drapery fabrics are employed.Other fabrics have been treated with materials which, while providingadvantageous reflectivity and transmittance characteristics, areobjectionable with respect to their absorptivity properties. Thus thetreated fabric not only absorbs a substantial amount of heat or energybut it also re-radiates it in an energy or heat-deficient direction. Inother words, in an instance where a fabric is made into a drapery ordrapery liner, and the conditions are such that a room in which suchdraperies are employed is at a norm-a1 room temperature and thetemperature outside the room is considerably colder, the draperymaterial absorbs the energy or heat from the room in substantialquantities and reflects it to the colder area. Also, when the roomtemperature is cooler than an outside area, the drapery material absorbsheat or energy from the outside and reflects it within the room, thusdisadvantageously causing an elevation of the room temperature.Obviously, this latter phenomenon is particularly disadvantageous when,for instance, the fabric is utilized in an air-conditioned enclosure.

In addition to the foregoing disadvantages of existing coated or treatedfabrics, such fabrics generally are not considered to be washable ordry-cleanable which seriously impairs their practicality from aneconomic point of view.

It is therefore an object of the present invention to provide a fabricwith a novel coating which imparts thereto advantageous thermalinsulating characteristics.

It is another object of the present invention to provide a coated fabricthat is substantially opaque, yet possesses desirable reflectivity,transmittance and absorptivity characteristics and at the same time iswashable and dry cleanable without losing its effectiveness.

ttes Patent M Patented Jan. 3, 1967 It is a further object of theinvention to provide a coated fabric containing supplemental heat andlight refiective constituents held in place on the fabric by a syntheticresin cured in situ.

Yet a further object of the invention is to provide a composition forcoating a fabric.

Still another object of the present invention is to provide a washingand dry cleaning resistant composition for coating a fabric wherein thecomposition can be applied to the fabric as a cold aqueous solution ordispersion.

These and other objects of the invention will appear and be more fullyset forth in the following detailed description.

The fabric of the present invention can be a material which is, forinstance, a woven, nonwoven or knitted fabric made of natural orsynthetic fiber or blends thereof. For instance, the fabric can be arelatively open weave cotton material as bleached muslin, or it can bemade of other fibers such as acetate, silk, acrylonitrile, vinylchloride, polyethylene terephth-alate, polyethylene, vinylidenechloride, casein, viscose, and other fibers or blends of such fibers.

The coating of the invention comprises a filler and a catalyzedsynthetic resin binder, compounded preferably With a thickener and aplasticizer. Also the composition can, advantageously, contain othermaterials such as a light reflective constituent, an aqueous dispersionof a wear-resisting polymerized resin, and a wetting agent. Each of theabove-mentioned components is preferably combined as an aqueoussuspension, solution, dispersion or emulsion and the composition thusformed is applied to the fabric by conventional methods, such asdoctoring, and knife or roller coating onto the fabric. The syntheticresin of the composition is cured as by passing the cloth through aheating zone. It is surprising that although the composition is Waterbased, it is not dissolved by washing or dry cleaning after having beencured.

The filler employed in the novel coating composition of the instantinvention preferably is talc although other conventional fillers canalso be used. For instance, titaniurn dioxide can also be employed,especially in instances where a Whitening effect or additional opacityis desirable. The filler is employed in amounts of about 50 to weightpercent of the total composition and 1.2 to 2.8 pounds of filler perpound of synthetic resin binder on a water free basis are employed.

The synthetic resin binder is, preferably, selected from the groupconsisting of an alkali metal acrylic monomer and a lower alkyl acrylicmonomer or a mixture of such monomers and is, preferably, in the form ofabout a 50% solids in aqueous dispersion. A particular resin,advantageously, is an aqueous solution or dispersion of monomers such assodium acrylate and ethyl acrylate. Preferably, they are present, on anaqueous dispersionor solution-free basis, in amounts of about 25 to 50Weight percent of the total composition. Additionally, the resin can be,for instance, sodium methacrylate, ammonium acrylate, ammoniummethacrylate, methyl acrylate, methyl methacrylate, ethyl methacrylate,etc.

The polymerization catalyst employed in the instant invention,preferably, is an acid catalyst and can be for instance an organic orinorganic acid such as a di-carboxylic acid or mineral acid asphosphoric, sulfuric or even a halogen acid. Typical di-carboxylic acidsuseful with the present invention include oxalic, malonic,"succinic,glutaric, adipic, pimelic, suberic, :azelaic, sebacic, etc.Monocarboxylic and other di-carboxylic acids can also be used. Generallythe amount of catalyst used will depend on a number of factors, easilydetermined by those skilled in the art, such as the particular acrylicresin chosen, the amount of such resin, the curing temperature and timeutilized, the fabric chosen, etc. Usually the amount employed will besuch that on curing no excess remains which would otherwise, being in acrystalline state, attack the fibers of the fabric. Generally the amountwill range from about 0.08 to 0.16 weight percent of the total coatingcomposition.

A thickener, preferably a cellulose ether, is provided to impart tofinal composition the desired viscosity which will depend, again, on anumber of easily ascertainable factors such as the physicalcharacteristics of fabric being coated, i.e., open-weave, close-weave,nonwoven or knitted as well as the type, i.e., cotton, silk, syntheticfiber, etc. Also determinative of the amount of viscosity adjusteremployed will be the amounts and types of resin as well as catalystemployed to produce the final composition. Generally, however, theamount used will be sufiicient to provide a composition suflicientlyviscous to prevent striking through the face of the fabric but not soviscous that it prevents substantial filling of the interstices of thefabric. Usually this amount will be from about 2 to 6 weight percent,preferably about 4 weight percent of the final composition.

Other components of the novel coating composition which, advantageously,can be employed are a plasticizer such as a high molecular weighthydrocarbon oil or mixture of oils, used to soften the texture of thecoated fabric, and employed in amounts, generally from about to 10weight percent of the final composition. Typical commercially availableplasticizers are AG55 and Paraplex G- (Rohm and Haas).

A wetting agent such as an ionic, nonionic or anionic dispersing agentcan also be used. Preferably, a nonionic dispersing agent such as oneobtainable by condensing ethylene oxide with (a) a fatty acid containinga chain of at least 10 carbon atoms starting from and including about 1weight percent of the total composition. Also, if desired, conventionalinsulating constituents which supplement the thermal insulatingproperties achieved by the instant composition can also be used. Typicalconstituents are comminuted mica flakes, colloidal silica, comminutedasbestos and the like. When used, they will generally be present inamounts up to about 0.5 weight percent of the total composition. Each ofthe above-mentioned components is, preferably, combined as an aqueoussuspension, solution or dispersion and the composition thus formed isapplied to the fabric by doctoring, knife or roller coating or any otherconvenient method. The synthetic resin of the composition issubsequently cured by passing the fabric through a heating zonemaintained at a temperature ranging, generally, from about 300400 F. fora period of up to about 1 minute. Preferably, the time of exposure ofthe coated fabric to any heating treatment is dependent, of course, onthe exact temperature chosen. Thus an exposure time will generally beinversely proportional to the temperature employed. For instance, when atemperature of about 400 F. is employed, any given portion of the coatedfabric will generally be exposed to this temperature for a period ofabout seconds. Preferably, the temperature of the heating treatment isabout 375 to 380 F. and the time of exposure is about 1 minute.

After the synethic resin is cured on the fabric, the coated fabricadvantageously is subjected to a mechanical treatment such ascalendering or a mechanical or compressive shrinkage treatmentdepending, of course, on a number of easily ascertainable factors suchas the residual shrinkage of the fabric.

Example I The invention is best illustrated by the following example ofa drapery material. A coating composition was prepared from theconstituents as set forth.

, Constituent Trade name Acrylic resin Oxalie acid 'I E32 (Rohm & Haas)(Mixture of Monomers).

Form Amount solids (43.7% acrylic 260 lbs.

and 2.3 emulsifier solids) in aqueous dispersion. Crystalline dihydrate.14 ozs.

250 lbs.

24.- lbs.

Liquid to make 100 gallons total coating composition.

Dry Dispersed in hot Wate the carbon atoms of the carboxyl group, e.g.,lauric acid, palmitic acid or oleic acid with (b) a fatty alcoholcontaining a chain of at least 10 carbon atoms starting from andincluding the carbon atom carrying the hydroxyl group, e.g., laurylalcohol, cetyl alcohol or oleyl alcohol, or with an alkyl phenol inwhich the alkyl group contains a chain of at least four carbon atoms. Acommercial product representative of such a wetting agent is TritonX-lOO sold by Rohm and Haas. The wetting agent preferably is used inamount of up to about 1, preferably about 0.7 weight percent of thetotal composition.

In addition, the novel coating composition of this invention can alsocontain an aqueous dispersion of a wearresisting polymerized resin suchas polytetrafluoroethylene (Teflon) or trifluorochloroethylene (Kel-F).Other fluorocarbons can also be used and they are employed to aid inproviding ironability and dirt repellancy to the fabric. Generall thefluorocarbon on an aqueous dispersion-free basis is present in amountsof up to about 1 weight percent, preferably about 0.8 weight percentbased on the total composition. 7

Aqueous emulsions of silicones, for instance, polydialkyl ordiaryl-siloxanes such as polydimethylsiloxane and polydiphenylsiloxanecan also be incorporated into the coating composition in amountsranging, generally, up to The above composition was knife coated onto acontinuously conveyed web of acetate drapery fabric as to substantiallyfill the interstices of the fabric. The pickup was found to be anapproximate 50 percent of coating composition per weight of the fabricused. Cloth having more interstices would, of course, require a somewhatgreater amount of coating composition. The coated fabric was thenconveyed to a drying tower maintained at about 375380 P. where thecoating was dried and the acrylic resin cured. The fabric was passedtherethrough at a rate sutficient that any given portion of the fabricwas exposed to this heating treatment for a period of about 1 minute.

The coated drapery fabric was found to be substantially opaque andpossess effective thermal insulation. The drapery material coated withthe above composition is repeatedly washable and dry cleanable withoutsubstan tial loss of its softness, opaqueness and its thermal insulatingproperties. The washed drapery material showed a shrinkage of less than3 percent when tested according to method 5550, Federal Specification,CCC-T-l9lb (May 15, 1951) and the dry cleaned sample showed a shrinkageof less than /2 of 1 percent. Neither sample was puckered and bothshowed excellent shape retention.

Example II A coating composition as set forth in Example I was preparedand in addition it included the following conapparel lining, windowshades, mattress covers, bedspreads, and supports for decorative fabricsin general. All parts and percentages recited herein are on a weightbasis with respect to the final or total composition, which stituents. 5in turn is on a water-free basis.

Constituent Trade name Form Amount, lbs.

Polytetrafluoroethylene Teflon 30 (Du Pont) 16% solids in aqueous dis-30 Polydimethylsiloxane A5333? emulsion 2 Plasticizer (hydrocarbon G-30(Rohm & Haas) Hydocarbon oil 21 W f ting agent Triton X-100 (alkylarylLiquid 4 polyether alcohol).

The above composition was knife coated onto a con- It should also berealized that the examples set forth tinuously conveyed web of preshrunkbleached cotton above do not represent a limitation of the scope of themuslin fabric as to substantially fill the interstices of the inventionbut only serve to illustrate the principles therefabric. The pickup wasfound to be an approximate 50 of and that many variations can be made ofthe specific percent of coating composition per weight of the bleachedembodiments set forth without departing from the princloth used. Thecoated cloth was then conveyed to a ciples of the invention. Therefore,the invention is limdrying tower maintained at 350 F. where the coatingwas ited only by the spirit and scope of the appended claims. dried andthe acrylic resin cured. The coated liner was We claim: conveyed throughthe tower at a rate such that each point 1. A flexible, drapeable,washable and dry cleanable thereon had a contact period of about oneminute. coated fabric consisting essentially of a fabric completely Thecoated liner possessed substantially the same coated with a compositionconsisting essentially of a filler physical characteristics noted above.adapted to reflect a proportion of light waves while trans- Example "Imitting a proportion of said waves, with a minimum of heat absorption,and resinous binder consisting of an To a ooatlllg oomposltloncompounded as Set forth 111 acrylic polymer polymerized in situ on thefabric by an EXZHIIPIc II more Was additionally included two Pounds acidcatalyst, the proportions by weight of filler to binder of y ColloidalSilica (LudoX-Du and two Pounds being from 1.2 to 2.8 parts of fillerper part of binder. of y mioa flakes The composition Was roller Coated2. A washable and dry cleanable coated fabric having onto a continuouslyconveyed Web and then heat treated a balance of light reflectance,transmittance and absorpat 8 r about minute to y and Cure the tioncharacteristics consisting essentially of a fabric comacrylic resin. Thecured fabric exhibited substantially l l coated i h a compositioncomprising a hit the same advantageous characteristics described above.fill r d resinous bi consisting f an li poly- Example 1V mer polymerizedin situ on the fabric by an acid catalyst,

d t f th the proportions by weight of filler to binder being from g figi giggi g: 321 222 fi z gg g 1.2 to 2.8 of filler per part of hinder,the filler comprising was knife coated onto bleached muslin and driedand f Q to 75 percent by walght of the total lcomposl' cured in a dryingtower as above. A sample of fabric sohds' h h so coated was washed andanother sample was dry A fabljlc according to clfum W w 6 Propercleaned. After one cleaning cycle both samples of th 011 by WeIght offiller to blnder is approximately two fabric were found to have lost asubstantial portion of Parts filler P P of blodortheir coating. Uponexamination, it appeared that the A fabric according to olalm 2 in Whlohthe finer dry constituents of the coating, i.e., the mica, silica and istalc. g g g H s; -Fi f the i dThus f gg References Cited by the Examineroun a e aci ac mg as a ca a ys an crossg agent for the polymerization ofthe acrylic resin, causes UNITED STATES PATENTS the resin to become awash and dry clean-proof binder 2 129 5 9 1938 Barrett et 1 260 2 forthe above-mentioned constituents. 1 9 5 1943 smith 117 143 X Resultsequally comparable to those out ined n E am- 2 467 341 4/1949 Seymour 30 41 ples I-III are achieved by using other acid catalysts such 280786510/1957 Shippee et aL X as a phosphoric acid or its salt, for instance,diammonium 28928O4 6/1959 Crissey 260 41 phosphate, or otherdi-carboxylic acids, such as malonic, 3003987 10/1961 Hager g "f 5succinic adipic and the 3 035 002 5/1962 Brasure et a1 260-41 Thecoating composition of the invention can advantageously be used withother fabrics made of other natural and synthetic fibers or blendsthereof to provide, not only drapery and drapery liner materials but,for instance,

WILLIAM D. MARTIN, Primary Examiner.

W. D. HERRICK, Assistant Examiner.

1. A FLEXIBLE, DRAPEABLE, WASHABLE AND DRY CLEANABLE COATED FABRICCONSISTING ESSENTIALLY OF A FABRIC COMPLETELY COATED WITH A COMPOSITIONCONSISTING ESSENTIALLY OF A FILLER ADAPTED TO REFLECT A PROPORTION OFLIGHT WAVES WHILE TRANSMITTING A PROPORTION OF SAID WAVES, WITH AMINIMUM OF HEAT ABSORPTION, AND RESINOUS BINDER CONSISTING OF AN ACRYLICPOLYMER POLYMERIZED IN SITU ON THE FABRIC BY AN ACID CATALYST, THEPROPORTIONS BY WEIGHT OF FILLER TO BINDER BEING FROM 1.2 TO 2.8 PARTS OFFILLER PER PART OF BINDER.